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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

TEM characterization of two variants of fuel cladding chemical interaction in a HT-9 Clad U-10Zr Fuel. Variant 1: FCCI with a Zr Rind

Here, this study investigated the fuel cladding chemical interaction (FCCI), a key factor that limits operational temperature and burnup, in an HT-9 clad U-10Zr nuclear fuel sample irradiated to a high burnup of 13.1 at.% at a time-averaged peak inner cladding temperature (PICT) of 530 °C. Previous results showed this fuel sample exhibited two distinct levels of FCCI at d. This paper analyzed the FCCI at an azimuthal position showing an interdiffusion layer of <10 µm using transmission electron microscopy to examine chemical and crystallographic nature of phases at the fuel-cladding interface at the nanoscale level. A ZrC layer and a Zr 3 Si phase were identified at the interface; these, along with the relatively low local temperature, potentially contributed to limit interdiffusion, behaving as inhibitors for deleterious interactions. Lanthanides (Ln) partially consumed the ZrC layer and interacted with Fe, forming a Zr-Ln compound and a (Zr,Ce)Fe 2+x phase while also infiltrating up to 4 µm into the cladding. Neither U nor Zr were observed in the cladding, whereas Fe diffused up to 3–5 µm in the fuel. Fe infiltration formed a ternary U-Zr-Fe ε-phase and likely promoted the precipitation of a Cr-rich α’ phase on the cladding interface. Additionally, a Cr-rich χ-phase, likely formed by the dissociation of pre-existing M 23 C 6 carbide precipitates, was identified about 2–5 µm from the fuel-cladding interface. Irradiation-induced nano-voids were also observed in the HT-9 bulk. These findings provide critical insights into FCCI mechanisms at representative irradiation conditions, essential for developing models simulating in-pile metallic fuel behaviors for next-generation reactors.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Multidimensional modeling of fuel-cladding friction in an LWR fuel rod

Solving finite element problems with friction often increases the level of difficulty to obtain properly converged solutions. This type of challenge becomes more salient when advanced, possibly multiscale, material models are employed to capture the thermomechanical behavior of fuel and cladding materials. Here the present work details our recent developments in a nuclear fuel performance finite element code for the systematic consideration of friction in nuclear reactor finite element simulations. We show the application of friction and its effects on the mechanics of light-water reactor rods accounting for various fuel constitutive modeling techniques, model dimensionalities, pellet assumed geometries, and power conditions. In particular, we focus on the fuel rod mechanical behavior as it relates to fuel constitutive models, sensitivity to the coefficient of friction, pellet states of stress, and rod elongation. We discuss the trade-offs between the various multidimensional modeling options and highlight the relevance of frictional effects in the prediction of the fuel rod deformation and interfacial stresses. To relate our modeling results with actual reactor operation, simulations including frictional effects are compared with fuel rod elongation experimental data and some challenges for carrying out a full validation of the axial mechanics are discussed.

42 ENGINEERING↗
DOE OSTI2026

Cost-effective valorization of 2,3-butanediol to high-value chemicals and jet fuel

Here, this work outlines an optimized process for converting 2,3-butanediol (BDO) into sustainable aviation fuel (SAF) and C4 chemicals. BDO is reactively separated from fermentation broth by forming dioxolanes, which are converted to isobutyraldehyde, methyl ethyl ketone (MEK), and 1,3-butadiene. These intermediates are reduced and dehydrated over Cu/ZSM-5 to form alkenes, which can be oligomerized and hydrotreated to jet-range alkanes. Previous BDO-dioxolane-alkene processes are limited by the requirement for a continuous aldehyde source for dioxolane formation. Brønsted acidic zeolites catalyze dioxolane deacetalization to form isobutyraldehyde and MEK in a >2:1 molar ratio, providing an internal, recyclable aldehyde source. Dioxolane formation optimization was performed to achieve >95% dioxolane yields over Amberlyst-15 and minimize isobutyraldehyde recycle. The overall BDO-dioxolane-fuel process yields an alkane mixture that enables at least a 50% v/v blend with Jet-A. Techno-economic analyses and life cycle assessments for this BDO-dioxolane-fuel process yield scenarios with <$2.50 per gallon gas equivalent and >58% reduction in CO2 emissions.

2,3-butanediol↗
DOE OSTI2026

Recent Advances in Cladding Material Extraction from Fuels in Nuclear Fuel Cycles

An improved recycling and recovery process for the cladding material from spent nuclear fuels is very important toward confirming nuclear energy to support ongoing sustainable development of nuclear management by reducing waste and conserving resources. Nuclear spent fuel cladding materials such as zirconium alloys have economic values and can be recovered, and their recovery eliminates problems in waste disposal and conserves valuable resources. Over 110 published reports and journal articles are reviewed and summarized herein, with a main focus on documenting recovery techniques used to recover cladding materials from spent nuclear fuel and recent developments. Several recovery techniques which are used at present times, such as mechanical separation, chemical dissolution, and hydrometallurgical processes have been covered with examples and discussions. Difficulties within the recovery process are also discussed, and most probable areas for future research in improving efficiency and sustainability of recovering cladding material are identified and discussed at the end. Here, this review could be an important document to the field of spent nuclear fuel reprocessing, recovering valuables and thereby offering guidance on how to effectively manage, safely handle, and reduce nuclear waste. In addition to reducing the volume and radiotoxicity of high-level waste, this review also highlights the potential economic benefit of recovering zirconium from spent fuel cladding by relating typical zirconium metal prices to the mass of cladding per tonne of spent fuel, illustrating that the recoverable material value is non-negligible compared with back-end fuel-cycle costs.

Mondal, Kunal [Oak Ridge National Laboratory (ORNL↗
NASA NTRS1978

Impact of future fuel properties on aircraft engines and fuel systems

The effect of modifications in hydrocarbon jet fuels specifications on engine performance, component durability and maintenance, and aircraft fuel system performance is discussed. Specific topics covered include: specific fuel consumption; ignition at relight limits; exhaust emissions; combustor liner temperatures; carbon deposition; gum formation in fuel nozzles, erosion and corrosion of turbine blades and vanes; deposits in fuel system heat exchangers; and pumpability and flowability of the fuel. Data that evaluate the ability of current technology aircraft to accept fuel specification changes are presented, and selected technological advances that can reduce the severity of the problems are described and discussed.

Rudey, R. A.↗
NASA NTRS1979

Effect of broadened-specification fuels on aircraft engines and fuel systems

A wide variety of studies on the potential effects of broadened-specification fuels on future aircraft engines and fuel systems are summarized. The compositions and characteristics of aircraft fuels that may be derived from current and future crude-oil sources are described, and the most critical properties that may effect aircraft engines and fuel systems are identified and discussed. The problems that are most likely to be encountered because of changes in selected fuel properties are explored; and the related effects on engine performance, component durability and maintenance, and aircraft fuel-system performance are examined. The ability of current technology to accept possible future fuel specification changes is assessed and selected technological advances that can reduce the severity of the potential problems are illustrated.

Rudey, R. A.↗
NASA NTRS1979

Effect of broadened-specification fuels on aircraft engines and fuel systems

A wide variety of studies on the potential effects of broadened-specification fuels on future aircraft engines and fuel systems are summarized. The compositions and characteristics of aircraft fuels that may be derived from current and future crude-oil sources are described, and the most critical properties that may affect aircraft engines and fuel systems are identified and discussed. The problems that are most likely to be encountered because of changes in selected fuel properties are described; and the related effects on engine performance, component durability and maintenance, and aircraft fuel-system performance are discussed. The ability of current technology to accept possible future fuel-specification changes is discussed, and selected technological advances that can reduce the severity of the potential problems are illustrated.

Rudey, R. A.↗
NASA NTRS1980

Experimental Study of Turbine Fuel Thermal Stability in an Aircraft Fuel System Simulator

The thermal stability of aircraft gas turbines fuels was investigated. The objectives were: (1) to design and build an aircraft fuel system simulator; (2) to establish criteria for quantitative assessment of fuel thermal degradation; and (3) to measure the thermal degradation of Jet A and an alternative fuel. Accordingly, an aircraft fuel system simulator was built and the coking tendencies of Jet A and a model alternative fuel (No. 2 heating oil) were measured over a range of temperatures, pressures, flows, and fuel inlet conditions.

Vranos, A.↗
NASA NTRS1998

Fuel Injector Patternation Evaluation in Advanced Liquid-Fueled, High Pressure, Gas Turbine Combustors, Using Nonintrusive Optical Diagnostic Techniques

Planar laser-induced fluorescence (PLIF) imaging and planar Mie scattering are used to examine the fuel distribution pattern (patternation) for advanced fuel injector concepts in kerosene burning, high pressure gas turbine combustors. Three diverse fuel injector concepts for aerospace applications were investigated under a broad range of operating conditions. Fuel PLIF patternation results are contrasted with those obtained by planar Mie scattering. Further comparison is also made for one injector with data obtained through phase Doppler measurements. Differences in spray patterns for diverse conditions and fuel injector configurations are readily discernible. An examination of the data has shown that a direct determination of the fuel spray angle at realistic conditions is also possible. The results obtained in this study demonstrate the applicability and usefulness of these nonintrusive optical techniques for investigating fuel spray patternation under actual combustor conditions.

Locke, R. J.↗
NASA NTRS1998

Optical Fuel Injector Patternation Measurements in Advanced Liquid-Fueled, High Pressure, Gas Turbine Combustors

Planar laser-induced fluorescence (PLIF) imaging and planar Mie scattering are used to examine the fuel distribution pattern (patternation) for advanced fuel injector concepts in kerosene burning, high pressure gas turbine combustors. Three fuel injector concepts for aerospace applications were investigated under a broad range of operating conditions. Fuel PLIF patternation results are contrasted with those obtained by planar Mie scattering. For one injector, further comparison is also made with data obtained through phase Doppler measurements. Differences in spray patterns for diverse conditions and fuel injector configurations are readily discernible. An examination of the data has shown that a direct determination of the fuel spray angle at realistic conditions is also possible. The results obtained in this study demonstrate the applicability and usefulness of these nonintrusive optical techniques for investigating fuel spray patternation under actual combustor conditions.

Locke, R. J.↗
NASA NTRS1997

System for operating solid oxide fuel cell generator on diesel fuel

A system is provided for operating a solid oxide fuel cell generator on diesel fuel. The system includes a hydrodesulfurizer which reduces the sulfur content of commercial and military grade diesel fuel to an acceptable level. Hydrogen which has been previously separated from the process stream is mixed with diesel fuel at low pressure. The diesel/hydrogen mixture is then pressurized and introduced into the hydrodesulfurizer. The hydrodesulfurizer comprises a metal oxide such as ZnO which reacts with hydrogen sulfide in the presence of a metal catalyst to form a metal sulfide and water. After desulfurization, the diesel fuel is reformed and delivered to a hydrogen separator which removes most of the hydrogen from the reformed fuel prior to introduction into a solid oxide fuel cell generator. The separated hydrogen is then selectively delivered to the diesel/hydrogen mixer or to a hydrogen storage unit. The hydrogen storage unit preferably comprises a metal hydride which stores hydrogen in solid form at low pressure. Hydrogen may be discharged from the metal hydride to the diesel/hydrogen mixture at low pressure upon demand, particularly during start-up and shut-down of the system.

Singh, Prabhu↗
DOE OSTI2025

Experimental Investigation of Air-Fuel Equivalence Ratio Effects on Advanced Dual-fuel Diesel/Ammonia Combustion on a Single-Cylinder Medium-Duty Diesel Engine at High Load

Ammonia (NH3) has gathered a lot of interest as a low-lifecycle-carbon fuel in sectors with high weight and distance requirements, such as shipping. The International Maritime Organization (IMO) mandates a 70-80% greenhouse gas (GHG) reduction by 2040, which is only possible with advanced engine technologies and fuels like NH3. Prior research studies at the US Department of Energy’s Oak Ridge National Laboratory have shown strong performance with NH3 under dual-fuel mode using conventional diesel combustion (CDC) manifold air pressure (MAP) settings. Diesel airflow was initially used to simplify retrofitting (no turbocharger modification), which resulted in air-fuel equivalence ratios (λ) greater than 1.5. To characterize potential improvements in dual-fuel NH3 combustion performance at richer in-cylinder conditions, a global λ sweep using a diesel pilot ignition (DPI) strategy with diesel fuel injected near top-dead center (TDC) and a reactivity-controlled compression ignition (RCCI) injection strategy with diesel fuel injected earlier during the compression stroke were compared. The experiments were conducted at 1200 RPM and 12.6 bar (75% load), and λ was varied by decreasing the commanded air flow to the engine at greater than 90% ammonia energy substitution (AES) level. A diesel injection timing sweep was conducted for both the combustion modes at fixed λ, and the timing with the lowest engine-out N2O emissions was identified. The results indicated an optimal balance between CO2, eq and thermal efficiency benefits for both DPI and RCCI injection strategy cases compared to CDC at a λ of 1.4. The indicated N-based emissions exhibited a strong correlation to the ratio of CA5–50 and ignition delay for DPI, but no apparent trend emerged for the RCCI injection strategy at the tested boundary conditions.

Tyrewala, Daanish [ORNL] (ORCID:0000000208599324)↗
DOE OSTI2025

Transmission Electron Microscopy Characterization of Fuel Cladding Chemical Interaction between Minor Actinides bearing U-Pu-Zr Fuel and AIM1 Cladding

Minor actinides (MA) significantly contribute to the long-term radiotoxicity of spent nuclear fuel (SNF). Separating MA from SNF and incorporating it into metallic fuels for fast reactor transmutation is a potential method to reduce this radiotoxicity. Here, this study focuses on transmission electron microscopy characterization of two samples from the fuel cladding chemical interaction (FCCI) region of an americium (Am) and neptunium (Np)-bearing (MA-bearing) uranium-plutonium-zirconium (U-Pu-Zr) fuel irradiated in the Phenix fast reactor to 9.5 % FIMA burnup at approximately 550 °C cladding temperature. The results show that despite the complex chemical interactions between MA and AIM1 cladding elements, excessive FCCI was not induced, and Am penetration depth in the cladding limited to less than 4 µm. Np remained mostly inside fuel. The Zr-rich compounds layer effectively limited the accumulation of lanthanide on the inner cladding surface. Overall, the FCCI behavior between investigated MA-bearing U-Pu-Zr fuel and AIM1 cladding is benign.

Chemical interaction↗
DOE OSTI2025

Fuel Assembly and Irradiation Parametric Study for Extended-Enrichment and High-Burnup Light-Water Reactor Spent Nuclear Fuel in Dry Storage Casks and Transportation Packages

There is an increased interest in operating commercial light-water reactors (LWRs) in the United States with improved economics that would result from longer fuel cycle lengths, fewer and shorter refueling outages, and fewer fuel assemblies requiring storage at the back end of the fuel cycle. To support this, fuel discharge burnups, as well as initial 235 U enrichments, must be higher than those used in current commercial LWRs. The typical upper limit considered for assembly average burnup in this report is 75 gigawatt-days (GWd) per metric ton of uranium (MTU), as opposed to the current typical upper bound of approximately 62 GWd/MTU. The upper limit considered for initial 235 U enrichment is 8 weight percent (8 wt %), as opposed to the current regulatory limit of 5 wt %. The enrichment range from 5 to 8 wt % is referred to in this report as extended enrichment . To investigate the effect of high burnup and extended enrichment conditions on dose rates and burnup credit for dry storage casks and transportation packages, a fuel assembly and irradiation parametric study was performed. The conclusions from this study will assist U.S. Nuclear Regulatory Commission staff in reviewing applications for dry storage casks and transportation packages that contain high-burnup and extended enrichment fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Development of New Reactor Core Configuration for Power Uprate - Fuel Reload & Heat Processing Analyses, Core Design, System Safety Assessments, and Fuel Performance Analyses

With the passage of the Infrastructure Investment and Jobs Act in 2021 and the Inflation Reduction Act (IRA) in 2022, the United States stands at a critical juncture for the future of nuclear power. These landmark policies provide significant support for clean energy initiatives, positioning nuclear power as a key component of the nation’s strategy to reduce carbon emissions and achieve energy security. This growing emphasis on nuclear energy is driven by the need for reliable, low-carbon power sources as the country transitions away from fossil fuels. Federal policy, along with increasing state-level support, is encouraging investment in nuclear technology advancements to meet these demands. Building new nuclear power plants (NPPs), however, presents significant challenges due to high costs and long construction timelines. As a result, increasing the power output of existing NPPs through power uprates has emerged as a more feasible and cost-effective strategy. One key area of advancement is the development of accident-tolerant fuel (ATF), such as chromium-coated zirconium alloy cladding, which offers enhanced material performance, enabling power uprates in light water reactors (LWRs). Given the growing demand for nuclear energy fueled by federal policies and state initiatives, it is essential to evaluate the feasibility and benefits of significant power uprates in existing pressurized water reactors (PWRs) using advanced fuel technologies. The introduction of ATF concepts opens new opportunities for safely and economically achieving these power increases. Assessing whether these innovations can support substantial power uprates while maintaining operational safety is crucial to maximizing the potential of the nation’s existing nuclear infrastructure. This project aims to explore how power uprates can be achieved by boosting reactor thermal power output and optimizing reactor core design, while ensuring the safety and economic viability of NPPs. Specifically, it will focus on demonstrating the technical and economic feasibility of power uprates in a PWR using low 5-10% enrichment uranium (LEU+) high burnup (HBU) fuel combined with ATF concepts. In fiscal year 2024 (FY24), the research and development focus on building foundational models and conducting multi-physics performance and safety analyses to support the power uprate. The findings of the study would be shared through LWRS Seasonal Meetings, conferences and workshops with utility companies and researchers. These also serve as a basis for further study of fuel reloading optimization with ATF claddings.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1975

Combustor exhaust emissions with air-atomizing splash-groove fuel injectors burning Jet A and Diesel number 2 fuels

Air-atomizing, splash-groove injectors were shown to improve primary-zone fuel spreading and reduce combustor exhaust emissions for Jet A and diesel number 2 fuels. With Jet A fuel large-orifice, splash-groove injectors the oxides-of-nitrogen emission index was reduced, but emissions of carbon monoxide, unburned hydrocarbons, or smoke were unaffected. Small-orifice, splash-groove injectors did not reduce oxides of nitrogen, but reduced the smoke number and carbon monoxide and unburned-hydrocarbon emission indices. With diesel number 2 fuel, the small-orifice, splash-groove injectors reduced oxides of nitrogen by 19 percent, smoke number by 28 percent, carbon monoxide by 75 percent, and unburned hydrocarbons by 50 percent. Smoke number and unburned hydrocarbons were twice as high with diesel number 2 as with Jet A fuel. Combustor blowout limits were similar for diesel number 2 and Jet A fuels.

Ingebo, R. D.↗
NASA NTRS1980

Fuels research: Fuel thermal stability overview

Alternative fuels or crude supplies are examined with respect to satisfying aviation fuel needs for the next 50 years. The thermal stability of potential future fuels is discussed and the effects of these characteristics on aircraft fuel systems are examined. Advanced fuel system technology and design guidelines for future fuels with lower thermal stability are reported.

Cohen, S. M.↗